Computer-aided progressive die design system and method

ABSTRACT

According to one embodiment of the invention, a computerized method for designing a progressive die used in the manufacturing of a part formed from sheet metal includes receiving, at a computer, information regarding one or more features of the part, and determining, by the computer, a blank layout for the part based on the features of the part and the number of parts desired. The computer further determines one or more details of a strip for the blank layout, information regarding a die base based on the details of the strip, and information regarding one or more inserts for die plates of the die base based on operations of the processes needed to form the features in the part. The computerized method further includes generating, by the computer, one or more outputs associated with the progressive die.

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates generally to the computer-aideddesign (“CAD”) industry and, more particularly, to a computer-aidedprogressive die design system and method.

BACKGROUND OF THE INVENTION

[0002] Progressive dies are used to transform flat strips of sheet metalinto a formed part. This transformation is performed progressively by aseries of stations that cut, punch, form, and bend the material into adesired shape. A progressive die that performs the various formingoperations on the material is unique for every part. The variouscomponents that make up the die are located in guided and precision cutopenings in plates, which are in turn located and guided by pins. Theentire die is actuated by a mechanical press that moves the die up anddown, and the sheet metal is fed through the die progressing from onestation to the next.

[0003] Progressive die design is a relatively complex and highlyiterative process. When a die company receives a design from a customer,for example, it is common practice to remodel the components using thedie company's own system, the original drawings, or a 3D model. The nextstep involves process planning. This involves unfolding, blank layout,scrap design and strip layout. Then the main die structure must beaddressed. This normally includes the die base design, in addition to agreat number of inserts, standard parts, and relief design depending onthe complexity of the part being manufactured. After this stage iscomplete the detailed drawings are produced for the progressive die.Each step is a relatively manual one. Consequently, it is time-consumingand expensive. In addition, design modifications to the initial partmust be run through the entire process manually, largely due to the lackof associativity among the different systems that are employed. A greatamount of design knowledge and experience is required.

[0004] Today's progressive die manufacturers face a number of issuesthat hold back improvements in productivity, quality, and turnaroundtime. These range from a lack of experienced progressive die designers,the difficulties involved in speeding up and improving quality in themore traditional design methods, and a shortage of any specific,easy-to-use, productive software solutions for progressive die design.In order to maintain their competitive edge and survive, more and moreprogressive die companies are looking to adopt three-dimensionalcomputer-aided design (“3D CAD”) technology.

SUMMARY OF THE INVENTION

[0005] According to one embodiment of the invention, a computerizedmethod for designing a progressive die used in the manufacturing of apart formed from sheet metal includes receiving, at a computer,information regarding one or more features of the part, and determining,by the computer, a blank layout for the part based on the features ofthe part and the number of parts desired. The computer furtherdetermines one or more details of a strip for the blank layout,information regarding a die base based on the details of the strip, andinformation regarding one or more inserts for die plates of the die basebased on operations of the processes needed to form the features in thepart. The computerized method further includes generating, by thecomputer, one or more outputs associated with the progressive die.

[0006] Embodiments of the invention provide a number of technicaladvantages. Embodiments of the invention may include all, some, or noneof these advantages. In one embodiment, a computer-aided progressive diedesign method captures an industry's specific process knowledge,promotes the most efficient work flow, and links complex elements ofdesign technology into automated sequences. What once was only in theminds of experts may now be easily utilized by less experienced people.By automatically extracting sheet metal features and mapping them toprocess features, representing a company's design standards, users cancapture a multitude of designs. Efficient and easy-to-use blank layoutdesign tools enable designers to efficiently lay out process features innumerous operation stations while minimizing material scrap. Once done,3D strip layout simulations provide immediate feedback for design andprocess changes. In addition, customizable die base libraries, standardpart libraries, and insert group libraries expedite the die structuredesign and ensure that users' complete processes are handledeffectively.

[0007] Other technical advantages are readily apparent to one skilled inthe art from the following figures, descriptions, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a more complete understanding of the invention, and forfurther features and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

[0009]FIG. 1A is a block diagram illustrating a computer-aidedprogressive die design system according to one embodiment of theinvention;

[0010]FIG. 1B is a block diagram of a computer in the system of FIG. 1for use in designing progressive dies according to one embodiment of theinvention;

[0011]FIG. 2 is a flowchart illustrating a computerized method ofdesigning a progressive die according to one embodiment of theinvention;

[0012]FIG. 3A is a flowchart illustrating a computerized method ofreceiving information regarding one or more features of a part accordingto one embodiment of the invention;

[0013]FIG. 3B is an example Project Initialization user interface usedin the method of FIG. 3A;

[0014]FIG. 4A is a flowchart illustrating a computerized method ofreceiving information regarding one or more processes and theirassociated operations according to one embodiment of the invention;

[0015]FIG. 4B is an example Feature Process Define user interface usedin the method of FIG. 4A;

[0016]FIG. 4C is an example Process Selection sub-user interface used inthe method of FIG. 4A;

[0017]FIG. 5A is a flowchart illustrating a computerized method ofdetermining a blank layout for a part based on the features of the partand the number of parts desired according to one embodiment of theinvention;

[0018]FIG. 5B is an example Blank Layout user interface used in themethod of FIG. 5A;

[0019]FIG. 6A is a flowchart illustrating a computerized method ofdetermining one or more details of a strip for a blank layout accordingto one embodiment of the invention;

[0020]FIG. 6B is an example Scrap Design user interface used in themethod of FIG. 6A;

[0021]FIG. 6C is an example Strip Layout user interface used in themethod of FIG. 6A;

[0022]FIG. 7 is a flowchart illustrating a computerized method ofdetermining information regarding a die base based on details of a stripaccording to one embodiment of the invention;

[0023]FIG. 8A is a flowchart illustrating a computerized method ofreceiving information regarding one or more inserts for die plates of adie base according to one embodiment of the invention;

[0024]FIG. 8B is an example Insert Group Design user interface used inthe method of FIG. 8A;

[0025]FIG. 8C is an example Standard Part Management sub-user interfaceused in the method of FIG. 8A; and

[0026]FIG. 9 is a flowchart illustrating a computerized method ofgenerating one or more outputs associated with a progressive dieaccording to one embodiment of the invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

[0027] Example embodiments of the present invention and their advantagesare best understood by referring now to FIGS. 1 through 9 of thedrawings, in which like numerals refer to like parts.

[0028]FIG. 1a is a block diagram illustrating a computer-aidedprogressive die design system 100 according to one embodiment of thepresent invention. System 100 includes a progressive die design company102 employing a progressive die designer 104 having access to a computer200 and a printer 108. Progressive die design company 102 may be anycompany or other suitable entity that designs progressive dies.Progressive die design company 102 often has a goal of producinghigh-quality progressive dies within short lead-times. Becauseprogressive die design is a relatively complex and highly iterativeprocess, the present invention provides a computerized method and systemfor designing progressive dies used in manufacturing parts formed fromsheet metal. Some embodiments of the present invention capture theindustry's specific process knowledge, promote the most efficientworkflow, and link complex elements of progressive die design technologyinto automated sequences. This computerized method is utilized byprogressive die designer 104, which may be either an individual employeeor a group of employees employed by progressive die design company 102.

[0029]FIG. 1B is a block diagram of computer 106 for use in designingprogressive dies according to one embodiment of the present invention.As illustrated, computer 106 includes an input device 110, an outputdevice 112, a processor 114, a memory 116 storing progressive die designapplication 118, a rules database 120, a parts and materials database122, a processes and operations database 124, a blank and strip database126, and a die base and insert group database 128.

[0030] Input device 110 is coupled to computer 106 for allowingprogressive die designer 104 to utilize progressive die designapplication 118. For example, as discussed below, progressive diedesigner 104 utilizes progressive die design application 118 through aseries of user interfaces contained within progressive die designapplication 118. This allows progressive die designer 104 to input,select, and/or manipulate various data and information. In oneembodiment, input device 110 is a keyboard; however, input device 110may take other forms, such as a mouse, a stylus, a scanner, or anycombination thereof. Output device 112 is any suitable visual displayunit, such as a liquid crystal display (“LCD”) or cathode ray tube(“CRT”) display, that allows progressive die designer 104 to see theprogressive die and/or its components as it is being designed. Outputdevice 112 may also be coupled to printer 108 for the purpose ofprinting any desired information, such as detailed drawings, bills ofmaterials, or other suitable information.

[0031] Processor 114 comprises any suitable type of processing unit thatexecutes logic. One of the functions of processor 114 is to retrieveprogressive die design application 118 from memory 116 and executeprogressive die design application 118 to allow progressive die designer104 to design progressive dies. Other functions of progressive diedesign application 118 are discussed more fully below in conjunctionwith FIGS. 2 through 9. Processor 114 may also control the retrievingand/or storing of information and other suitable data, such as parts andmaterials information, processes and operations information, blank andstrip data, or die base and insert group information.

[0032] Progressive die design application 118 is a computer programwritten in any suitable computer language. According to the teachings ofthe present invention, progressive die design application 118 isoperable to utilize data and information stored in databases 120 through128 and input by progressive die designer 104 for the purpose ofdesigning progressive dies. Progressive die design application 118 mayperform other suitable functions, such as controlling the printing ofany of various outputs via printer 108. The functions of progressive diedesign application 118 are described below in conjunction with FIGS. 2through 9.

[0033] Memory 116 and databases 120 through 128 may comprise files,stacks, databases, or other suitable organizations of volatile ornonvolatile memory. Memory 208 and databases 120 through 128 may berandom-access memory, read-only memory, CD-ROM, removable memorydevices, or any other suitable devices that allow storage and/orretrieval of data. Memory 116 and databases 120 through 128 areinterchangeable and may perform the same functions. Details of databases120 through 128 are described below in conjunction with the descriptionof FIGS. 2 through 9. Briefly, rules database 120 stores various rules,formulas, tables, and other suitable logic that allows progressive diedesign application 118 to perform its function when designing aprogressive die. Parts and materials database 122 stores information onsheet-metal parts and various sheet-metal materials. Processes andoperations database 124 stores information regarding various processesand their associated operations that are used in a progressive die tomanufacture a part. Blank and strip database 126 stores informationregarding blanks and strips used in manufacturing sheet-metal parts. Diebase and insert group 128 stores information regarding die bases and thevarious insert groups used in die plates of a progressive die.

[0034]FIG. 2 is a flowchart illustrating a computerized method ofdesigning a progressive die according to one embodiment of the presentinvention. The computerized method outlined in FIG. 2, as well as thecomputerized methods outlined below in FIGS. 3A through 9 may beexecuted by progressive die design application 118 on computer 106 withthe interaction of progressive die designer 104, or through othersuitable techniques.

[0035] The method begins at step 300 where information regarding one ormore features of a sheet-metal part is received by progressive diedesign application 118. Generally, the information received at this stepis a mathematical representation of a sheet-metal part and itsassociated features that is desired to be manufactured with aprogressive die. The mathematical representation may be obtained fromany suitable geometric modeling. Details of step 300 are outlined belowin conjunction with FIGS. 3A and 3B.

[0036] Information regarding one or more processes and their associatedoperations needed to form features in the part is received byprogressive die design application 118 at step 400. Generally, based oninformation contained within rules database 120, progressive die designapplication 118 retrieves parameters of one or more processes and theirassociated operations from processes and operations database 124 basedon the type of features in the part. Or, progressive die designapplication 118 may receive parameters of the processes and theirassociated operations from progressive die designer 104 via input 110.Details of step 400 are outlined below in conjunction with FIGS. 4Athrough 4C.

[0037] A blank layout for the part is determined by progressive diedesign application 118 at step 500. This blank layout is based on thefeatures of the part and the number of parts desired. Generally,progressive die design application 118 determines a blank for the partbased on the mathematical model that was received at step 300.Progressive die design application 118 also determines a blank layoutfor the part via other information that is received from progressive diedesigner 104 or retrieved from blank and strip database 126 afterrequests from progressive die designer 104. Details of step 500 aredescribed below in conjunction with FIGS. 5A and 5B.

[0038] One or more details of a strip for the blank layout is determinedby progressive die design application 118 at step 600. Generally, basedon inputs received from progressive die designer 104 regarding a strip,progressive die design application 118 determines one or more details ofthe strip, such as dimensions for the strip, feed direction, number ofstations, scrap design, and press force center for the progressive die.This step may also entail simulating the operations of the processes onthe strip in three dimensions to determine whether or not anymodifications need to be made at this point in the design. Details ofstep 600 are outlined below in conjunction with FIGS. 6A through 6C.

[0039] Information regarding a die base is determined by progressive diedesign application 118 at step 700 based on the details of the strip. Adie base includes various die plates, such as a stripper plate, abottoming plate, a punch plate, etc. Generally, progressive die designapplication 118 retrieves a die base template from die base and insertgroup database 128 so that progressive die designer 104 may input editsfor the die base and its configurable items. Details of step 700 aredescribed below in conjunction with FIG. 7.

[0040] Information regarding one or more inserts for die plates of thedie base is received by progressive die design application 118 at step800 based on the processes and their associated operations. Generally,progressive die design application 118 receives a design of all theinsert groups required for the die plates of the die base. These designsare retrieved from data and information stored in die base and insertgroup database 128. The insert group designs are retrieved byprogressive die design application 118 so that progressive die designer104 may modify the design of one or more insert groups. Relief designand pocket design for the die plates are also performed at this step, asdescribed in further detail below. Details of step 800 are describedbelow in conjunction with FIGS. 8A through 8C.

[0041] One or more outputs associated with a progressive die isgenerated at step 900. Generally, progressive die design application 118generates any suitable output related to a progressive die, such asdetailed drawings, bills of material, and a hole table. These outputsmay be printed by printer 108. Details of step 900 are outlined below inconjunction with FIG. 9.

[0042]FIG. 3A is a flowchart illustrating a computerized method ofreceiving information regarding one or more features of a part accordingto one embodiment of the present invention. Other embodiments mayperform this method in a different manner. Progressive die designer 104is prompted at step 301 with a Project Initialization user interface350, an example of which is shown in FIG. 3B. At step 302, informationregarding a part including its features is received by progressive diedesign application 118. Progressive die design application 118 mayretrieve this part information from parts and materials database 122 byusing an “Open” tab 352 as shown in user interface 350. If new partinformation is being received, then a “New” tab 354 is utilized byprogressive die designer 104. As described above, part informationincludes a mathematical description of a sheet-metal part that isdesired to be formed by a progressive die. If new part information isreceived at step 302, then progressive die design application 118 maystore this part information in parts and materials database 122, asindicated by step 303. Parts may be stored in parts and materialsdatabase 122 by using an “Insert Part” button 356 or removed by using a“Remove Parts” button 358 in user interface 350.

[0043] A project path and name of a project is received at step 304 viaa “Project Path and Name” screen box 360. In addition, dimensional unitsfor the part are received at step 306 as a result of progressive diedesigner 104 selecting the appropriate Metric or English tab as shown at“Unit” box 362 in user interface 350. A sheet metal material for thepart is received at step 308 by progressive die designer 104 selecting amaterial either contained within parts and materials database 122 orentering a new material. If a new material is entered, then thismaterial may be stored in parts and materials database 122 using “EditMaterial Base” button 364. When progressive die designer 104 issatisfied with the information in user interface 350, then the “OK” or“Apply” button is clicked so that the information may be captured byprogressive die design application 118 and stored in the appropriateplace for later use.

[0044]FIG. 4A is a flowchart illustrating a computerized method ofreceiving information regarding one or more processes and theirassociated operations according to one embodiment of the presentinvention. Other embodiments may perform this method in a differentmanner. The method begins at step 401 where progressive die designer 104is prompted with a Feature Process Define user interface 450, an exampleof which is illustrated in FIG. 4B. Through user interface 450,progressive die designer 104 may select, remove, or edit variousprocesses and their associated operations in designing a progressivedie. Although not required, progressive die designer 104 may editstandard processes at step 402 by using an “Initialize Process” tab 451of user interface 450. For example, standard processes may be stored inprocess and operations database 124 for later use. The operationsassociated with a stored process may be modified by progressive diedesigner 104 using “Initialize Process” tab 451. In addition,“Initialize Process” tab 451 may be used for other suitable functions,such as updating a sheet-metal part, as indicated by step 404, iffeatures are added to a sheet-metal part after being received byprogressive die design application 118.

[0045] When progressive die designer 104 selects a “Standard Process”tab 452 of user interface 450, features of the part and their associatedprocesses are displayed, as indicated by step 406. For example, afeature list 453 may contain a list of features, such as a hole, anotch, a bend, a slot, or other suitable feature. The associatedprocesses used to manufacture these features are also listed in adefined processes list 454.

[0046] At step 408, one or more processes and their associatedoperations needed to form one or more features in the part are received.These processes are listed in defined processes list 454 of userinterface 450. These processes are automatically listed by progressivedie design application 118 based on the features of the part listed infeature list 453. Progressive die design application 118 retrieves theseprocesses from processes and operations database 124. Progressive diedesigner 104 may use a “Define Process” button 455 to specify detailsfor a particular process. If progressive die designer 104 selects“Define Process” button 455, then a Process Selection user interface 460pops up. An example of Process Selection user interface 460 isillustrated in FIG. 4C.

[0047] As illustrated in FIG. 4C, progressive die designer 104 mayselect the process type by using a pull-down menu 461. Any sub-types ofthis process are shown in a sub-type box 462 and any associatedoperations for this sub-type are shown in an operations box 463.Progressive die designer 104 may add sub-types to a process using userinterface 460. In addition, operations associated with these subtypesare input using user interface 460. Parameters of operations may bedefined by progressive die designer 104 using a parameters box 464. Thiscoincides with step 410, in which parameters for an operation arereceived by progressive die design application 118. Progressive diedesigner 104 clicks OK or Apply when finished with defining a standardprocess. Standard processes may also be removed from the definedprocesses list by pressing a “Remove Process” button 456.

[0048] New processes and their associated operations may be received atstep 412. This is accomplished using a “User Defined Process” tab 457 ofuser interface 450. Although the details of the user-defined process tapare not illustrated, generally, progressive die designer 104 may inputuser defined processes and their associated operations and associatethem with a particular part feature. Parameters for these new processesand their operations may be received at step 414. These new processesmay be stored in processes and operations database 124 at step 416 forlater use.

[0049]FIG. 5A is a flowchart illustrating a computerized method fordetermining a blank layout for a part based on the features of the partand a number of parts desired according to one embodiment of the presentinvention. Other embodiments may perform this method in a differentmanner. The method begins at step 501 where a blank for a part isdetermined by progressive die design application 118. The blank is basedon the part information (i.e., the mathematical representation of thepart) that was received by progressive die design application 118 abovein step 300. Progressive die design application 118, based on themathematical representation of the part, can unfold the part to create ablank for the part. Progressive die designer 104 may interactivelydesign a blank layout by using this blank via a Blank Layout userinterface 550, an example of which is shown in FIG. 5B. Accordingly, atstep 502, progressive die designer 104 is prompted with Blank Layoutuser interface 550.

[0050] At step 504, part revisions are received and the blank updated byprogressive die design application 118 by utilizing an “update blank”button (not shown). An additional blank for a different part may bereceived at step 506 if another part is desired to be manufactured withthe same progressive die being designed. An insert blank button 551 maybe used by progressive die designer 104 to accomplish this. Thisdifferent blank may be retrieved from blank and strip database 126. Abase point for one or more blanks are received at step 508 by utilizinga set base point button 552 as shown in user interface 550. This basepoint allows the blank to be rotated if so desired.

[0051] As indicated by step 510, various blank edits are received byprogressive die design application 118. This may include flipping theblank using a flip button 553, copying a blank by utilizing a copy blankbutton 554, deleting a blank by utilizing a delete blank button 555,shifting a blank in either an X direction or Y direction by utilizing a“Placement” section 556, and rotating a blank by utilizing Placementsection 556. In addition, a blank pitch may be received at step 512 byutilizing “Pitch & Width” section 557. Also shown in Pitch & Widthsection 557 is inputs for top and bottom web sizes for a strip.Accordingly, a strip web size is received by progressive die designapplication 118 at step 514. In addition, a strip width is determined atstep 516 by progressive die design application 118 from the blank dataand web size data input by progressive die designer 104. Finally, amaterial utilization percentage is determined at step 518 by progressivedie design application 118 to alert progressive die designer 104 of thematerial waste so that he or she may modify any design parameters toreduce the amount of material waste.

[0052]FIG. 6A is a flowchart illustrating a computerized method ofdetermining one or more details of a strip for a blank layout accordingto one embodiment of the present invention. Other embodiments mayperform this method in a different manner. The method begins at step 601where progressive die designer 104 is prompted with a Scrap Design userinterface 650 as shown in FIG. 6B. Scrap Design user interface 650allows progressive die designer 104 to design the scrap for the strip.Accordingly, assistant line information is received at step 602.Assistant lines are required to design scrap for the strip and are inputby progressive die designer 104 interactively using output device 112 ofcomputer 106.

[0053] Scrap edits are received by progressive die design application118, as indicated by step 604. A scrap design tools section 651 may beutilized to design the scrap for the strip. For example, a whole scrapdesign button 652 may be used to design the whole scrap, a split scrapdesign button 653 may be used to split the whole scrap or larger scrapsinto scraps with simple geometry, two scraps may be merged by utilizinga merge scrap button 654, or progressive die designer 104 may insertuser-defined scraps utilizing a user-defined scrap button 655. Othersuitable scrap edits may be received, such as deleting a user-definedscrap or moving a scrap. The method continues at step 606 were anoverlap for a scrap is received. Progressive die designer 104 mayutilize an overlap design section 656 to select an edge of a scrap wherean overlap will be added and to enter an appropriate overlap value. Anovercut for an overlap may be received at step 608. Progressive diedesigner 104 may utilize an overcut design section 657 to add overcutcorners to a scrap overlap. In this section, progressive die designer104 selects one end side of an overlap of the specified scrap, entersthe parameters of a reasonable overcut, and chooses the Apply button toshow the result or the OK button to accept. The method then continues atstep 610, as outlined below.

[0054] At step 610, progressive die designer 104 is prompted with aStrip Layout user interface 660, an example of which is shown in FIG.6C. Strip Layout user interface 660 allows progressive die designer 104to design a strip. Using an “Initialize Strip” tab 661, progressive diedesigner 104 may input a feed direction for the strip. This feeddirection is received by progressive die design application 118, asindicated by step 612. Progressive die design application 118 alsoreceives the number of stations for the strip at step 614. This is alsoinput by progressive die designer 104 utilizing Initialize Strip tab661. Both the feed direction and the number of stations may be modifiedat a later time.

[0055] At step 616, both laid and unlaid process sub-types and theirassociated station numbers are listed in a “Layout Process” tab 662. Anexample of a “Layout Process” tab 662 is shown in FIG. 6C. Utilizing“Layout Process” tab 662, processes and sequence edits are received byprogressive die designer 118, as indicated by step 618. This is whereprogressive die designer 104 may add or delete processes and/or theirsub-types for a particular part feature and/or determine a sequence forthe process and/or process sub-types. In other words, progressive diedesigner 104 may specify which process or process sub-type is utilizedin a particular station. Referring to FIG. 6C, a pull-down menu 663 maybe used to select the part feature. Progressive die design application118 automatically, based on the part feature selected, lists both thelaid and unlaid processes and/or process sub-types and theircorresponding station based on rules contained in rules database 120.Progressive die designer 104 may then add or remove processes and/orprocess sub-types from a laid process list 664 and also select whichstation a particular process is to be performed.

[0056] The method continues at step 620 where station edits are receivedby progressive die design application 118. This may include moving astation via a “Move” button 665 and/or inserting an idle station byutilizing an “Insert Idle” button 666. The method then continues at step622 where a strip layout is determined by progressive die designapplication 118. A “Load Design” button 667 may be utilized for thisstrip layout. A particular strip layout may be stored in blank and stripdatabase 126 at step 624 by utilizing a “Save Design” button 668 asshown.

[0057] Once the strip layout is designed by via Strip Layout userinterface 660, a simulation of the operations of the processes on thestrip is executed by progressive die design application 118. In oneembodiment, this simulation is carried out in three-dimensions (“3-D”)so that progressive die designer 104 may be alerted to any potentialinterferences or any other problems associated with the processes and/ortheir associated operations when forming features in the part. Based onthis simulation, progressive die designer 104 may modify the processsub-types and/or their operations by utilizing Strip Layout userinterface 660. These modifications are received, as indicated by step628, by progressive die design application 118 before another simulationis run. This simulation avoids having to actually construct a physicalprogressive die to determine any interferences or other problems, whichsaves considerable time and money in designing a progressive die.Another important advantage is that a 3-D simulation is much more usefulto progressive die designer 104 because it is much easier to view andevaluate things, such as a strip, in three dimensions than it is in twodimensions.

[0058] The method continues at step 630 where a press force associatedwith each operation is determined by progressive die design application118. Accordingly, a press force center for the progressive die isdetermined at step 632. This allows progressive die designer 104 todetermine the press setup for a particular progressive die and itsassociated press force. It also may alert progressive die designer 104to any potential problems based on the operations used to formparticular features in a part.

[0059]FIG. 7 is a flowchart illustrating a computerized method ofdetermining information regarding a die base based on details of a stripaccording to one embodiment in the present invention. Other embodimentsmay perform this method in a different manner. The method begins at step701 where progressive die designer 104 is prompted with a ProgressiveDie Base Management user interface (not shown). This user interfaceallows progressive die designer 104 to generally design the die base andits associated die plates. In addition, it allows progressive diedesigner 104 to configure the configurable items of the die base.

[0060] At step 702, a die base size is determined, based on the stripdetails determined above, by progressive die design application 118.Progressive die design application 118 may retrieve a die base templatefrom die base and insert group database 128 to start with. This die basetemplate is loaded at step 704 with its associated configurable items.Edits for the configurable items for the die base may be received, asindicated by step 706. These configurable items are such things as dieplates, guide posts, screw/fasteners, dowel pins, guide lifter sets, andstripper springs. The details of these configurable items are containedin die base and insert group database 128 so that progressive diedesigner 104 may use a Standard Part Management user interface (notshown) to configure these configurable items. Once all edits arereceived for the configurable items, the die base configuration isupdated at step 708 by progressive die design application 118.

[0061] Die base and/or die plate edits are received at step 710. Thismay include, for example, rotating the die base, moving the die base,editing the die base, splitting a die plate, or other suitable die plateedits. A “Design Tools” tab (not shown) of the Progressive Die BaseManagement user interface may be used to edit the die base and/or thedie plates. Accordingly, the die base and die plates are updated at step712 by progressive die design application 118, which ends the methodillustrated in FIG. 7.

[0062]FIG. 8A is a flowchart illustrating a computerized method forreceiving information regarding one or more inserts for die plates of adie base according to one embodiment of the present invention. Otherembodiments may perform this method in a different manner. The methodbegins at step 801 where progressive die designer 104 is prompted withan Insert Group Design user interface 850, an example of which is shownin FIG. 8B. User interface 850 allows progressive die designer 104 todesign the insert groups for the die plates. Based on the features ofthe part, and the processes, process sub-types, and operations used toform the features, progressive die design application 118 automaticallyloads details of certain insert groups from die base insert groupdatabase 128. For example, when progressive die designer 104 isdesigning the piercing insert group using a “Piercing” tab 851, he orshe may use a sub-user interface 860 as shown in FIG. 8C. Sub-userinterface 860 lists details of a standard piercing insert group designand allows progressive die designer 104 to modify the design informationbased on the progressive die's needs. Each of the insert groups requiredare designed similarly.

[0063] As indicated by step 802, piercing insert group information isreceived by progressive die design application 118. This is facilitatedby “Piercing” tab 851 as shown in FIG. 8B. Insert Design user interface850 includes other tabs such as a “Bending” tab 852, an “Embossing” tab853, a “Burring” tab 854, a “Lifter” tab 855, a “Pilot” tab 856, a“Mounting” tab 857, and a “Tool” tab 858 to design the insert groups. AStandard Part Management user interface 860 is available for each of theinsert groups so that progressive die designer 104 may specify theparameters for a particular insert group.

[0064] Referring back to FIG. 8A, bending insert group information isreceived by progressive die design application 118, as indicated by step804. This may include the type of bend, the bend area, the details forthe bend insert, and the details for the mating insert to bend thefeature.

[0065] Embossing insert group information is received by progressive diedesign application 118, as indicated by step 806. This may include theembossing faces, loading the embossing inserts, and designing the patchinsert head.

[0066] Burring insert group information is received by progressive diedesign application 118, as indicated by step 808. This may includedesigning the burring insert and positioning the burring insert.

[0067] Lifter insert group information is received by progressive diedesign application 118, as indicated by step 810. This may includedesigning the type of lifter, selecting the point for the lifter, andselecting the strip edge for the lifter. Lifters are used to lift thesheet-metal strip so it may be moved from station to station.

[0068] Pilot insert group information is received by progressive diedesign application 118, as indicated by step 812. This may includedesigning the pilot insert and positioning the pilot. The pilot lengthmay also be calculated at this step.

[0069] Mounting insert group information is received by progressive diedesign application 118, as indicated by step 814. This may includeselecting the type of mounting faces and designing the mounting inserts.The mounting insert group is for designing the type of mounting of thevarious punches and dies to the die plates.

[0070] Insert group edits are received by progressive die designapplication 118, as indicated by step 816. This is accomplished with thehelp of “Tool” tab 858. This may include such things as rotating aninsert group, moving an insert group to another position, removing aselected insert group, copying a selected insert group, or creating anarray of a selected insert group.

[0071] Because of the various features of the part, relief cavities mustbe utilized. Accordingly, relief cavity information is received byprogressive die design application 118, as indicated by step 820. ARelief Design user interface (not shown) is used to allow progressivedie designer 104 to design a relief type. For example, one or more solidbodies are created to cut out pockets and holes and other suitablecavities on the die plates to avoid interferences between the featuresformed in the strip and the die plates. For example, there may be threekinds of relief bodies: block, cylinder and user-defined. Progressivedie designer 104 has the ability to mathematically describe the type ofrelief. Once the relief is designed, progressive die designer 104 isprompted, at step 822, with a Create Pockets user interface (not shown).Accordingly, pocket information is received at step 824. This pocketinformation is utilized by progressive die design application 118 toautomatically create pockets according to the insert groups. After thepockets information is received, the die base and die plates are updatedat step 826, which ends the method outlined in FIG. 8A.

[0072]FIG. 9 is a flowchart illustrating a computerized method ofgenerating one or more outputs associated with a progressive dieaccording to one embodiment of the present invention. Other embodimentsmay perform this method in a different manner. The method begins at step901 where progressive die designer 104 is prompted with an OutputPreferences user interface (not shown). This user interface allowsprogressive die designer 104 to select what outputs he or she desiresand allows progressive die designer 104 to specify how the die base, dieplates, insert groups, etc., are displayed on output device 112.Progressive die designer 104 preferences on desired outputs arereceived, as indicated by step 902. This may include providing a tool tolet the designer 104 control a progressive die components' color andvisibility, or specify what type of printouts are desired. For example,at step 904, detailed drawings for the progressive die and itscomponents may be generated. In addition, bills of material for theprogressive die may be generated at step 906, or a hole table for theprogressive die may be generated at step 908. Printer 108 may be used toprint these desired outputs. Other suitable outputs may be specified bydesigner 104.

[0073] Thus, the present invention provide a computerized method andsystem for designing progressive dies used in manufacturing parts formedfrom sheet metal. Some embodiments of the present invention capture theindustry's specific process knowledge, promote the most efficientworkflow, and link complex elements of progressive die design technologyinto automated sequences. What once was only in the minds of experts maynow be easily utilized by less experienced people. By automaticallyextracting sheet metal features and mapping them to process features,representing a company's design standards, users can capture a multitudeof designs. Efficient and easy-to-use blank layout design tools enabledesigners to efficiently lay out process features in numerous operationstations while minimizing material scrap. Once done, 3D strip layoutsimulations provide immediate feedback for design and process changes.In addition, customizable die base libraries, standard part libraries,and insert group libraries expedite the die structure design and ensurethat users' complete processes are handled effectively.

[0074] Although embodiments of the invention and their advantages aredescribed in detail, a person skilled in the art could make variousalterations, additions, and omissions without departing from the spiritand scope of the present invention as defined by the appended claims.

What is claimed is:
 1. A computerized method for designing a progressivedie used in the manufacturing of a part formed from sheet metal,comprising: receiving, at a computer, information regarding one or morefeatures of the part; determining, by the computer, a blank layout forthe part based on the features of the part and the number of partsdesired; determining, by the computer, one or more details of a stripfor the blank layout; determining, by the computer, informationregarding a die base based on the details of the strip, the die basehaving a plurality of die plates; determining, by the computer,information regarding one or more inserts for the die plates based onone or more operations of one or more processes needed to form thefeatures in the part; and generating, by the computer, one or moreoutputs associated with the progressive die.
 2. The computerized methodof claim 1, further comprising: determining, by the computer, the one ormore processes needed to form the features in the part; determining, bythe computer, the one or more operations associated with each process;and receiving, at the computer, one or more parameters associated witheach operation.
 3. The computerized method of claim 1, furthercomprising: receiving, at the computer, information regarding one ormore scrap profiles for the strip; receiving, at the computer, asequence of the operations of the processes; simulating, by thecomputer, the operations of each process on the strip; notifying, via avisual display unit, a user of one or more results of the simulatingstep; and receiving one or more modifications of at least one parameterof at least one operation.
 4. The computerized method of claim 1,further comprising: receiving, at the computer, one or more parametersassociated with one or more configurable items for the die plates. 5.The computerized method of claim 1, further comprising: receiving, atthe computer, one or more parameters associated with the inserts;determining, by the computer, one or more relief cavities for the dieplates; and generating, by the computer, one or more pockets for the dieplates.
 6. The computerized method of claim 1, further comprising:determining, by the computer, a press force associated with eachoperation; and determining, by the computer, a press force center forthe progressive die based on the press force associated with eachoperation.
 7. The computerized method of claim 1, wherein determining,by the computer, one or more details of the strip for the blank layoutcomprises receiving, at the computer, a feed direction of the strip, awidth of the strip, and a length of the strip based on the number ofstations for the progressive die.
 8. The computerized method of claim 1,wherein generating, by the computer, one or more outputs associated withthe progressive die comprises generating a printout selected from thegroup consisting of at least one assembly drawing, a bill of material,and a hole table.
 9. A computerized method for designing a progressivedie used in the manufacturing of a part formed from sheet metal,comprising: receiving, at a computer, information regarding one or morefeatures of the part; determining, by the computer, one or moreprocesses needed to form the features in the part; determining, by thecomputer, one or more operations associated with each process;receiving, at the computer, one or more parameters associated with eachoperation; determining, by the computer, a blank layout for the partbased on the features of the part and the number of parts desired;determining, by the computer, one or more details of a strip for theblank layout; receiving, at the computer, information regarding one ormore scrap profiles for the strip; receiving, at the computer, asequence of the operations of the processes; simulating, by thecomputer, the operations of the processes on the strip; determining, bythe computer, information regarding a die base based on the details ofthe strip, the die base having a plurality of die plates; receiving, atthe computer, one or more parameters associated with one or moreconfigurable items for the die plates; determining, by the computer,information regarding one or more inserts for the die plates based onthe operations of the processes needed to form the features in the part;receiving, at the computer, one or more parameters associated with theinserts; determining, by the computer, one or more relief cavities forthe die plates; generating, by the computer, one or more pockets for thedie plates; and generating, by the computer, one or more outputsassociated with the progressive die.
 10. The computerized method ofclaim 9, further comprising: determining, by the computer, a press forceassociated with each operation; and determining, by the computer, apress force center for the progressive die based on the press forceassociated with each operation.
 11. The computerized method of claim 9,further comprising: notifying, via a visual display unit, a user of oneor more results of the simulating step; and receiving one or moremodifications of at least one parameter of at least one operation. 12.The computerized method of claim 9, wherein determining, by thecomputer, one or more details of the strip for the blank layoutcomprises receiving, at the computer, a feed direction of the strip, awidth of the strip, and a length of the strip based on the number ofstations for the progressive die.
 13. The computerized method of claim9; wherein generating, by the computer, one or more outputs associatedwith the progressive die comprises generating a printout selected fromthe group consisting of at least one assembly drawing, a bill ofmaterial, and a hole table.
 14. A system for designing a progressive dieused in the manufacturing of a part formed from sheet metal, comprising:a computer-readable medium; a computer program stored on thecomputer-readable medium operable to: receive information regarding oneor more features of the part; determine a blank layout for the partbased on the features of the part and the number of parts desired;determine one or more details of a strip for the blank layout; determineinformation regarding a die base based on the details of the strip, thedie base having a plurality of die plates; determine informationregarding one or more inserts for the die plates based on one or moreoperations of one or more processes needed to form the features in thepart; and generate one or more outputs associated with the progressivedie.
 15. The system of claim 14, wherein the computer program is furtheroperable to: determine the one or more processes needed to form thefeatures in the part; determine the one or more operations associatedwith each process; and receive one or more parameters associated witheach operation.
 16. The system of claim 14, wherein the computer programis further operable to: receive information regarding one or more scrapprofiles for the strip; receive a sequence of the operations of theprocesses; simulate the operations of each process on the strip; notify,via a visual display unit, a user of one or more results of thesimulating step; and receive one or more modifications of at least oneparameter of at least one operation.
 17. The system of claim 14, whereinthe computer program is further operable to: receive one or moreparameters associated with one or more configurable items for the dieplates.
 18. The system of claim 14, wherein the computer program isfurther operable to: receive one or more parameters associated with theinserts; determine one or more relief cavities for the die plates; andgenerate one or more pockets for the die plates.
 19. The system of claim14, wherein the computer program is further operable to: determine apress force associated with each operation; and determine a press forcecenter for the progressive die based on the press force associated witheach operation.
 20. The system of claim 14, wherein the computer programis further operable to receive a feed direction of the strip, a width ofthe strip, and a length of the strip based on the number of stations forthe progressive die.
 21. The system of claim 14, wherein the computerprogram is further operable to generate a printout selected from thegroup consisting of at least one assembly drawing, a bill of material,and a hole table.
 22. A system for designing a progressive die used inthe manufacturing of a part formed from sheet metal, comprising: acomputer-readable medium; a computer program stored on thecomputer-readable medium operable to: receive information regarding oneor more features of the part; determine one or more processes needed toform the features in the part; determine one or more operationsassociated with each process; receive one or more parameters associatedwith each operation; determine a blank layout for the part based on thefeatures of the part and the number of parts desired; determine one ormore details of a strip for the blank layout; receive informationregarding one or more scrap profiles for the strip; receive a sequenceof the operations of the processes; simulate the operations of theprocesses on the strip; determine information regarding a die base basedon the details of the strip, the die base having a plurality of dieplates; receive one or more parameters associated with one or moreconfigurable items for the die plates; determine information regardingone or more inserts for the die plates based on the operations of theprocesses needed to form the features in the part; receive one or moreparameters associated with the inserts; determine one or more reliefcavities for the die plates; generate one or more pockets for the dieplates; and generate one or more outputs associated with the progressivedie.
 23. The system of claim 22, wherein the computer program is furtheroperable to: determine a press force associated with each operation; anddetermine a press force center for the progressive die based on thepress force associated with each operation.
 24. The system of claim 22,wherein the computer program is further operable to: notify, via avisual display unit, a user of one or more results of the simulatingstep; and receive one or more modifications of at least one parameter ofat least one operation.
 25. The system of claim 22, wherein the computerprogram is further operable to receive a feed direction of the strip, awidth of the strip, and a length of the strip based on the number ofstations for the progressive die.
 26. The system of claim 22, whereinthe computer program is further operable to generate a printout selectedfrom the group consisting of at least one assembly drawing, a bill ofmaterial, and a hole table.